US2005042433A1PendingUtilityA1

Liner panel having barrier layer

52
Priority: Aug 20, 2003Filed: Aug 20, 2003Published: Feb 24, 2005
Est. expiryAug 20, 2023(expired)· nominal 20-yr term from priority
Inventors:John M. JonesCharles R. FetzDaniel J. MccormackMaung Aye Than
B32B 27/00B32B 2255/02B32B 7/12B32B 2307/514Y10T428/249924B32B 27/36B32B 2262/101B32B 15/046B32B 2307/304B32B 2262/0276B32B 2255/10Y10T156/1093B60P 3/00B32B 5/18B32B 2262/106B32B 27/32B32B 5/08B32B 5/024B32B 27/12Y10T156/1095B32B 27/18B32B 2255/06B32B 2260/00B32B 15/20B32B 2307/546Y10T156/1097B32B 2607/00B32B 15/18B32B 2307/7242B32B 27/065B32B 2266/0278B32B 2262/06B32B 2605/00B32B 2255/205
52
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Claims

Abstract

A cargo trailer includes a floor, a roof and a side wall extending vertically upward between the floor and roof. The side wall includes a substantially gas impermeable outer liner panel and a substantially gas impermeable inner liner panel. The inner liner panel includes at least one glass and polymer layer and one gas impermeable barrier layer. The inner liner panel can also be used to form the roof and replace the outer liner panel.

Claims

exact text as granted — not AI-modified
1 . A composite liner panel for use in a thermal insulated wall structure, comprising: 
 a. at least one gas impermeable barrier layer;    b. at least one structural polymer resin layer disposed coplanar and attached to said barrier layer, thereby forming a laminate liner panel; and    c. an insulated core layer disposed coplanar to said at least one gas impermeable barrier layer.    
     
     
         2 . The composite liner panel of  claim 1 , wherein said structural polymer resin layer is fiber reinforced.  
     
     
         3 . The composite liner panel of  claim 1 , wherein said structural polymer resin layer is strengthened by orienting the polymer molecules.  
     
     
         4 . The composite liner panel of  claim 1 , wherein said polymer resin is a thermoplastic polymer.  
     
     
         5 . The composite liner panel of  claim 4 , wherein said thermoplastic polymer is polypropylene.  
     
     
         6 . The composite liner panel of  claim 5 , wherein said at least one gas impermeable barrier layer is a metallized polyester film.  
     
     
         7 . The composite liner panel of  claim 1 , further comprising a first adhesive layer intermediate said barrier layer and said at least one structural polymer resin layer and attaching said barrier layer and said at least one structural polymer resin layer.  
     
     
         8 . The composite liner panel of  claim 1 , wherein said at least one gas impermeable barrier layer is a metallized polypropylene film.  
     
     
         9 . The composite liner panel of  claim 1 , wherein said at least one gas impermeable barrier layer is a metal foil.  
     
     
         10 . The composite liner panel of  claim 9 , further comprising an adhesive layer coplanar with and intermediate said at least one foil layer and said at least one structural polymer resin layer and attaching said at least one foil layer and said at least one structural polymer resin layer.  
     
     
         11 . The composite liner panel of  claim 1 , further comprising a scrim layer intermediate said at least one barrier layer and said insulated core layer.  
     
     
         12 . The composite liner panel of  claim 1 , further comprising a surface film layer.  
     
     
         13 . The composite liner panel of  claim 12 , wherein said surface film layer is a polymer.  
     
     
         14 . The thermal insulated composite wall panel of  claim 13 , wherein said surface film layer polymer is polypropylene.  
     
     
         15 . The composite liner panel of  claim 11 , wherein said scrim layer is formed from fibers.  
     
     
         16 . The composite liner panel of  claim 15 , wherein said fibers are glass.  
     
     
         17 . The composite liner panel of  claim 11 , wherein said fibers are polyester.  
     
     
         18 . The composite liner panel of  claim 7 , further comprising a second structural polymer resin layer coplanar with said at least one gas impermeable barrier layer located on the opposite side of said first structural polymer resin layer.  
     
     
         19 . The composite liner panel of  claim 18 , wherein said second polymer resin is polypropylene.  
     
     
         20 . The composite liner panel of  claim 18 , further comprising a second adhesive layer coplanar with and intermediate said at least one gas impermeable barrier layer and said second structural polymer resin layer and attaching said barrier layer and said second structural polymer resin layer.  
     
     
         21 . The composite liner panel of  claim 1 , wherein said polymer resin is a thermoset material.  
     
     
         22 . The composite liner panel of  claim 21 , wherein said barrier layer is sprayed onto said thermoset material.  
     
     
         23 . The composite liner panel of  claim 21 , wherein said barrier layer is sputtered onto said thermoset material.  
     
     
         24 . The composite liner panel of  claim 21 , wherein said barrier layer is adhesively bonded to said thermoset material.  
     
     
         25 . The composite liner panel of  claim 1 , wherein said insulated core layer is gas impregnated rigid foam.  
     
     
         26 . The composite liner panel of  claim 7 , wherein said adhesive layer further comprises a film.  
     
     
         27 . The composite liner panel of  claim 20 , wherein said second adhesive layer further comprises a film.  
     
     
         28 . A composite liner panel for use in a thermal insulated wall structure, comprising: 
 a. an insulating core layer;    b. at least one gas impermeable barrier layer that is coplanar with and attached to said insulating core layer; and    c. at least one structural polymer resin layer disposed coplanar to and consolidated with said barrier layer, thereby forming a laminate liner panel.    
     
     
         29 . The cargo compartment of  claim 28 , wherein said at least one structural polymer resin layer is fiber reinforced.  
     
     
         30 . The composite liner panel of  claim 28 , wherein said structural polymer resin is polypropylene.  
     
     
         31 . The composite liner panel of  claim 30 , wherein said at least one gas impermeable barrier layer is a metallized polyester film.  
     
     
         32 . The composite liner panel of  claim 28 , further comprising a first adhesive layer coplanar with and intermediate said at least one barrier layer and said at least one structural polymer resin layer attaching said barrier layer to said at least one structural polymer resin layer.  
     
     
         33 . The composite liner panel of  claim 28 , wherein said at least one gas impermeable barrier layer is a metallized polypropylene film.  
     
     
         34 . The composite liner panel of  claim 28 , wherein said at least one gas impermeable barrier layer is a metal foil.  
     
     
         35 . The composite liner panel of  claim 33 , further comprising an adhesive layer coplanar with and intermediate said at least one foil layer and said at least one structural polymer resin layer attaching said at least one foil layer to said at least one structural polymer resin layer.  
     
     
         36 . The composite liner panel of  claim 28 , further comprising a polymer scrim layer intermediate said insulating core and said at least one barrier layer.  
     
     
         37 . The composite liner panel of  claim 28 , further comprising a surface film layer disposed coplanar to and boded with said at least one structural polymer layer.  
     
     
         38 . The composite liner panel of  claim 37 , wherein said surface film layer comprises polypropylene.  
     
     
         39 . The composite liner panel of  claim 32 , further comprising a second structural polymer resin layer coplanar with said at least one gas impermeable barrier layer and located on the opposite side of said first structural polymer resin layer.  
     
     
         40 . The composite liner panel of  claim 39 , wherein said second structural polymer is polypropylene.  
     
     
         41 . The composite liner panel of  claim 39 , further comprising a second adhesive layer coplanar with and intermediate said at least one barrier layer and said second structural polymer resin layer attaching said barrier layer to said at least one structural polymer resin layer.  
     
     
         42 . The composite liner panel of  claim 36 , said scrim layer further comprising fibers.  
     
     
         43 . The composite liner panel of  claim 42 , wherein said fibers are polyester.  
     
     
         44 . A method for forming a composite liner panel for use in a thermal insulated wall structure, comprising: 
 a. providing 
 at least one gas impermeable barrier layer,  
 at least one structural polymer resin layer disposed coplanar to said barrier layer, and  
 a thermal insulated core layer  
   b. bonding said at least one gas impermeable barrier layer to said at least one structural polymer layer, thereby forming a laminate liner panel;    c. attaching said laminate liner panel to said thermal insulated core layer.    
     
     
         45 . The method for forming a composite liner panel of  claim 44 , step (b) further comprising heating said at least one gas impermeable barrier layer and said at least one structural polymer resin layer and compressing together said at least one gas impermeable barrier layer and said at least one structural polymer resin layer.  
     
     
         46 . The method for forming a composite liner panel of  claim 45 , further comprising cooling said laminate after step (b).  
     
     
         47 . The method for forming a composite liner panel of  claim 44 , wherein said structural polymer is a thermoset material.  
     
     
         48 . The method for forming a composite liner panel of  claim 47 , step (b) further comprising providing an adhesive intermediate said barrier layer and said at least one structural polymer resin layer attaching said barrier layer to said at least one structural polymer resin layer.  
     
     
         49 . The method for forming a composite liner panel of  claim 47 , step (b) further comprising spraying said barrier layer onto said at least one structural polymer resin layer.  
     
     
         50 . The method for forming a composite liner panel of  claim 45 , wherein said at least one gas impermeable barrier layer is a metallized polyester film.  
     
     
         51 . The method for forming a composite liner panel of  claim 50 , further comprising providing a first adhesive layer intermediate said at least one metallized polyester film and said at least one structural polymer resin layer attaching said at least one metallized polyester film to said at least one structural polymer resin layer.  
     
     
         52 . The method for forming a composite liner panel of  claim 51 , wherein said at least one gas impermeable barrier layer is a metallized polypropylene film.  
     
     
         53 . The method for forming a composite liner panel of  claim 44 , wherein said at least one gas impermeable barrier layer is a metal foil.  
     
     
         54 . The method for forming a composite liner panel of  claim 51 , further comprising providing a second structural polymer resin layer coplanar to said at least one gas impermeable barrier layer and on the opposite side of said at least one structural polymer resin layer.  
     
     
         55 . The method for forming a composite liner panel of  claim 54 , further comprising providing a second adhesive layer intermediate said at least one metallized polyester film and said second structural polymer resin layer.  
     
     
         56 . The method for forming a composite liner panel of  claim 44 , wherein said structural polymer resin layer is fiber reinforced.  
     
     
         57 . The method for forming a composite liner panel of  claim 56 , wherein said fibers are glass.  
     
     
         58 . The method for forming a composite liner panel of  claim 55 , further comprising providing a scrim layer coplanar with and intermediate said second structural polymer resin layer and said insulated core layer.  
     
     
         59 . The method for forming a composite liner panel of  claim 44 , wherein said insulated core layer comprises gas impregnated foam core.  
     
     
         60 . The method for forming a composite liner panel of  claim 59 , wherein said insulated core layer further comprises polyurethane.  
     
     
         61 . A method for forming a composite liner panel for use in a thermal insulated wall structure, comprising: 
 a. providing 
 at least one gas impermeable barrier layer,  
 at least one structural polymer resin layer disposed coplanar to said barrier layer, and  
   b. bonding said at least one gas impermeable barrier layer to said at least one structural polymer layer by heating said at least one gas impermeable barrier layer and said at least one structural polymer resin layer and compressing together said at least one gas impermeable barrier layer and said at least one structural polymer resin layer thereby forming a laminate liner panel.    
     
     
         62 . The method for forming a composite liner panel of  claim 61 , further comprising cooling said laminate after step (b).  
     
     
         63 . The method for forming a composite liner panel of  claim 62 , step (b) further comprising providing an adhesive intermediate said barrier layer and said at least one structural polymer resin layer for attaching said barrier layer to said at least one structural polymer resin layer.  
     
     
         64 . The method for forming a composite liner panel of  claim 62 , step (b) further comprising spraying said barrier layer onto said at least one structural polymer resin layer.  
     
     
         65 . The method for forming a composite liner panel of  claim 61 , wherein said at least one gas impermeable barrier layer is a metallized polyester film.  
     
     
         66 . The method for forming a composite liner panel of  claim 65 , further comprising providing a first adhesive layer intermediate said at least one metallized polyester film and said at least one structural polymer resin layer for attaching said at least one metallized polyester film to said at least one structural polymer resin layer.  
     
     
         67 . The method for forming a composite liner panel of  claim 66 , wherein said at least one gas impermeable barrier layer is a metallized polypropylene film.  
     
     
         68 . The method for forming a composite liner panel of  claim 65 , wherein said at least one gas impermeable barrier layer is a metal foil.  
     
     
         69 . The method for forming a composite liner panel of  claim 66 , further comprising providing a second structural polymer resin layer coplanar to said at least one gas impermeable barrier layer and on the opposite side of said at least one structural polymer resin layer.  
     
     
         70 . The method for forming a composite liner panel of  claim 69 , further comprising providing a second adhesive layer intermediate said at least one metallized polyester film and said second structural polymer resin layer.  
     
     
         71 . The method for forming a composite liner panel of  claim 61 , wherein said structural polymer resin layer is fiber reinforced.  
     
     
         72 . The method for forming a composite liner panel of  claim 71 , wherein said fibers are glass.  
     
     
         73 . The method for forming a composite liner panel of  claim 70 , further comprising providing a scrim layer coplanar with and intermediate said second structural polymer resin layer.

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